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I was able to get some work done on the biceps and forearms. I finished glueing cover strips on the biceps: I made the inside strap hooks according to Tony's build: ...and used CA glue to attach them:

THX

Used to fly RC planes, now use servos for droid builds

Here goes nothing! OK - So i have FINALLY managed to get my shoulder bells sitting as close as possible to the chest plate. It was a pretty simple solution - make new shoulder bells, heat shaped them, replace the elastic shoulder bridge straps with nylon strapping and then beg my wife to take more photos. Any guesses for which of those steps was the hardest? *Original photo updated.

For an Original Trilogy Stormtrooper I would highly recommend getting a vac formed kit. It will be far less work, more accurate and probably cheaper too. For a First Order Stormtrooper there's a couple of options I believe for files. Again a lot of work to do this. You'll really want something big as its the seams where you join parts that end up being the biggest headache. Glens FDM suggestions above look like solid picks, I have no large printer experience. You could go resin but start adding 0s in material costs (especially if you pick the more suitable tough resins) and the machines get pricy fast as well once you get past the "Saturn" size class.